a small tip, try and get a set of 6inch / small files, their the shiz for finishing up cut outs neatly and they remove more metal, better then you might expect i use em a fair bit

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i have a 12" one with a round edge, yeah i was wishing i had smaller ones too. but since budget is very very limited so poo for me. the nose pliers u see here are 40yrs old. its my dads. they are 21yrs older than me LOL

also there need to be a slight modification to the top exhaust. my new PSU is 1 cm longer, so what i will do is cut out a rectangle and attach a shroud thingy (there will be 3, one at front, back and middle). the fans will be mounted on the shroud. shroud will be made of aluminum 1mm thick.

I'm astonished that you bought new fans, weren't you the fan repair man? Just j/k. Nice thread btw. New pictures would be nice too, just make sure you make it to the end. This is some nice modding you are doing with that case with the tools you have at hand, BRAVO!

Hey Das, could you use perspex for the fan mount? great stuff, thanks for posting love to see what folks are up too.
Good idea to get rid of the acer logo, hahaha.

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hmmm... you mean acrylic right?? yes, but i would have to find them. and they are hard to paint as i cant find adhesioner here in india.

also the fans would simple 50mm black ones. so nothing fancy to see.
I might, however put some slots in the fan mount and get some LEDs underneath. so far i have done the measurements for the mount only. 50mm x3 is a little bit cramped

Have you thought about whether you plan to paint it afterwards? A black matte finish would be nice, especially having worked the metal so much. The interior too should be given some paint love, lets not make it a half assed job lol

Well if you go for shiny paint jobs, just make sure you sand it well and smooth before. It doesn't hide imperfections as you say well, cause of light reflections etc, you get the drill. Matte would have made your job a tad easier. (dunna what you really plan to do with the sponge roller, so I might be out of tune here)